Hand-held electromechanical surgical system

ABSTRACT

A hand-held electromechanical surgical device is configured to selectively connect with a surgical accessory. The surgical device includes a power-pack, an outer shell housing, and a gasket. The power-pack is configured to selectively control a surgical accessory. The outer shell housing includes a distal half-section and a proximal half-section, the distal half-section and the proximal half-section together defining a cavity configured to selectively encase substantially the entire power-pack therein. The gasket is located between the distal half-section and the proximal half-section of the outer shell housing. The gasket is configured to create a seal between the distal half-section and the proximal half-section and to provide a sterile barrier between the power-pack and an outside environment outside the outer shell housing.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation application of U.S. patentapplication Ser. No. 16/367,456, filed on Mar. 28, 2019, which is aContinuation application of U.S. patent application Ser. No. 15/583,544,filed on May 1, 2017, now U.S. Pat. No. 10,245,056, which is aContinuation application of U.S. patent application Ser. No. 14/983,689,filed on Dec. 30, 2015, now U.S. Pat. No. 9,636,091, which is aContinuation-in-Part application of U.S. patent application Ser. No.14/865,843, filed on Sep. 25, 2015, now U.S. Pat. No. 9,456,873, whichis a Continuation application of U.S. patent application Ser. No.14/551,321, filed on Nov. 24, 2014, now U.S. Pat. No. 9,155,529, whichis a Continuation application of U.S. patent application Ser. No.13/719,344, filed on Dec. 19, 2012, now U.S. Pat. No. 8,894,647, whichclaims the benefit of and priority to U.S. Provisional PatentApplication No. 61/586,201, filed on Jan. 13, 2012, the entire contentsof each of which are incorporated by reference herein.

The present application relates to U.S. patent application Ser. No.15/445,500, filed on Feb. 28, 2017, now U.S. Pat. No. 9,987,029, whichis a Continuation application of U.S. patent application Ser. No.14/990,164, filed on Jan. 7, 2016, now U.S. Pat. No. 9,872,673, which isa Continuation application of U.S. patent application Ser. No.13/719,377, filed Dec. 19, 2012, now U.S. Pat. No. 9,241,757, the entirecontents of which are incorporated by reference herein.

BACKGROUND 1. Technical Field

The present disclosure relates to surgical devices. More specifically,the present disclosure relates to hand-held electromechanical surgicalsystems for performing surgical procedures.

2. Background of Related Art

Generally, a hand-held electromechanical surgical system includes apowered handle assembly, which is reusable, and a disposable endeffector or the like that is selectively connected to the powered handleassembly prior to use and then disconnected from the powered handleassembly following use in order to be disposed of or in some instancessterilized for re-use. The powered handle assembly may include a sterileouter shell housing and a power-pack selectively loadable into the outershell housing.

In order to maintain a sterile environment in the operating room, a needexists for a shell housing incorporating an improved seal between thepower-pack and the operating room.

SUMMARY

According to an aspect of the present disclosure, a hand-heldelectromechanical surgical device configured to selectively connect witha surgical accessory includes a power-pack, an outer shell housing, anda gasket. The power-pack is configured to selectively control a surgicalaccessory. The outer shell housing includes a distal half-section and aproximal half-section, the distal half-section and the proximalhalf-section together defining a cavity configured to selectively encasesubstantially the entire power-pack therein. The gasket is locatedbetween the distal half-section and the proximal half-section of theouter shell housing, the gasket configured to create a seal to provide asterile barrier between the power-pack and an outside environment.

The distal half-section may include a proximal facing edge and theproximal half-section may include a distal facing edge. In a firstposition, the proximal facing edge and the distal facing edge are spacedapart, and in a second position, the proximal facing edge and the distalfacing edge are approximated defining an interface therebetween. Thegasket may be disposed at the interface defined between the distalfacing edge of the proximal half-section of the outer shell housing, andthe proximal facing edge of the distal half-section of the outer shellhousing.

The proximal facing edge of the distal half-section of the outer shellhousing may define a groove configured to receive the gasket. The distalfacing edge of the proximal half-section may define a protrusionconfigured to engage the gasket, such that in the second position, atleast a portion of the gasket is nested in the groove defined in thedistal half-section when the proximal half-section and the distalhalf-section are approximated.

The gasket may include a reinforcing member configured to strengthen theseal between the distal half-section and the proximal half-section. Thereinforcing member may be configured to be nested in the groove definedin the distal half-section of the outer shell housing when the proximalhalf-section and the distal half-section are approximated.

An insertion guide positionable on the distal facing edge of theproximal half-section of the outer shell housing may be provided withthe electromechanical surgical device. The insertion guide is configuredto shield an outer surface of the outer shell housing from thepower-pack when the power-pack is being inserted into the cavity of theouter shell housing. The insertion guide may include a body defining atrack, the track configured to engage the distal facing edge of theproximal half-section of the outer shell. The gasket may be locatable inthe track of the insertion guide, such that, when the insertion guide isdisposed on the distal facing edge of the proximal half-section of theouter shell housing, the gasket is disposed on the distal facing edge ofthe proximal half-section of the outer shell housing. The insertionguide may include a mechanical release configured to release the gasketfrom the track.

According to an aspect of the present disclosure, a method of assemblinga hand-held electromechanical surgical device includes providing ahand-held electromechanical surgical device including an outer shellhousing, installing a gasket onto the outer shell housing, inserting thepower-pack into a receiving cavity of the outer shell housing whilemaintaining a sterility of the outer shell housing, and closing theouter shell housing to encase the power-pack therein.

Installing the gasket onto the outer shell housing may include removinga removable coating from a second side of the gasket and locating thesecond side of the gasket on a proximal half-section of the outer shellhousing. Installing the gasket onto the outer shell housing may furtherinclude inserting the gasket into a track defined in an insertion guideconfigured to guide the insertion of the power-pack into the receivingcavity of the outer shell housing, locating the insertion guide onto aproximal half-section of the outer shell housing such that the gasket islocated on a distal facing edge of the proximal half-section of theouter shell housing, and releasing the gasket from the track defined inthe insertion guide such that when the insertion guide is removed fromthe proximal half-section of the outer shell housing, the gasket remainslocated on the distal facing edge of the proximal half-section of theouter shell housing.

According to an aspect of the present disclosure, a kit including apower-pack, an electromechanical surgical device, and an insertion guideis provided. The electromechanical surgical device includes an outershell housing having a distal half-section and a proximal half-section,the distal half-section and the proximal half-section together defininga cavity configured to selectively encase substantially the entirepower-pack therein. The insertion guide is locatable on the distalfacing edge of the proximal half-section of the outer shell housing, theinsertion guide configured to shield an outer surface of the outer shellhousing from the power-pack when the power-pack is being inserted intothe cavity of the outer shell housing.

The insertion guide may include a body defining a track, the trackconfigured to engage the distal facing edge of the proximal half-sectionof the outer shell.

The kit may also include a gasket, wherein the gasket is positioned inthe track of the insertion guide, such that when the insertion guide isdisposed on the distal facing edge of the proximal half-section of theouter shell housing, the gasket is disposed on the distal facing edge ofthe proximal half-section of the outer shell housing.

The insertion guide may include a mechanical release configured torelease the gasket from the track therein.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure are described herein withreference to the accompanying drawings, wherein:

FIG. 1 is a perspective view of an electromechanical hand-held surgicaldevice and adapter assembly, in accordance with an embodiment of thepresent disclosure, illustrating a connection thereof with an endeffector;

FIG. 2 is a perspective view of the outer shell housing of theelectromechanical hand-held surgical device of FIG. 1;

FIG. 3 is a front perspective view, with parts separated, of the outershell housing of the electromechanical hand-held surgical device ofFIGS. 1 and 2;

FIG. 4 is a cross-sectional view of an embodiment of an interfacedefined in the outer shell housing of the electromechanical hand-heldsurgical device of FIG. 1;

FIG. 5A is a cross-sectional view of another embodiment of an interfacedefined in the outer shell housing of an electromechanical hand-heldsurgical device;

FIG. 5B is a cross-sectional view of yet another embodiment of aninterface defined in the outer shell housing of an electromechanicalhand-held surgical device;

FIG. 5C is a cross-sectional view of still another embodiment of aninterface defined in the outer shell housing of an electromechanicalhand-held surgical device;

FIG. 5D is a cross-sectional view of a further embodiment of aninterface defined in the outer shell housing of an electromechanicalhand-held surgical device;

FIG. 5E is a cross-sectional view of another embodiment of an interfacedefined in the outer shell housing of an electromechanical hand-heldsurgical device;

FIG. 5F is a cross-sectional view of yet another embodiment of aninterface defined in the outer shell housing of an electromechanicalhand-held surgical device;

FIG. 6 is a perspective view illustrating insertion of a power-pack intoan outer shell housing of an electromechanical hand-held surgicaldevice;

FIG. 7 is a perspective view illustrating the power-pack nested into theouter shell housing of the hand-held surgical device;

FIG. 8 is a perspective view illustrating insertion of a gasket into aninsertion guide for use with the hand-held surgical device;

FIG. 9 is a front view illustrating the power-pack nested into the outershell housing and the gasket located on the interface defined in theouter shell housing of the hand-held surgical device;

FIG. 10 is a kit including the electromechanical hand-held surgicaldevice according to FIG. 1, the gasket, and the insertion guide inaccordance with the present disclosure;

FIGS. 11A and 11B illustrate perspective views of a reusable surgicalinstrument module, in accordance with an embodiment of the presentdisclosure;

FIG. 12 illustrates a reusable surgical instrument module inserted intoan outer housing shell having a hinged instrument cover shell, inaccordance with an embodiment of the present disclosure;

FIG. 13 illustrates a reusable surgical instrument module inserted intoan outer housing shell having a snapable instrument cover shell, inaccordance with another embodiment of the present disclosure; and

FIG. 14 is an enlarged, schematic, longitudinal cross-sectional viewillustrating the reusable surgical instrument module inserted into theouter housing shell, and showing seals disposed about drive shafts ofthe reusable surgical instrument module.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed surgical devices, and adapterassemblies for surgical devices and/or handle assemblies are describedin detail with reference to the drawings, in which like referencenumerals designate identical or corresponding elements in each of theseveral views. As used herein the term “distal” refers to that portionof the adapter assembly or surgical device, or component thereof,farther from the user, while the term “proximal” refers to that portionof the adapter assembly or surgical device, or component thereof, closerto the user.

A surgical device, in accordance with an embodiment of the presentdisclosure, is generally designated as 100, and is in the form of apowered hand-held electromechanical instrument. The powered hand-heldelectromechanical instrument is configured for selective attachment ofan end effector thereto. The end effector can be actuated andmanipulated by the powered hand-held electromechanical surgicalinstrument.

As illustrated in FIG. 1, surgical device 100 is configured forselective connection with an adapter 200, and, in turn, adapter 200 isconfigured for selective connection with end effectors or single useloading units (“SULU's”) 400.

As illustrated in FIGS. 1-3, surgical device 100 includes a power-pack101 configured to selectively control end effector 400, and an outershell housing 10 configured to selectively receive and substantiallyencase power-pack 101. Power-pack 101 includes a battery, controlcircuitry and motors to actuate end effector 400. For a detailedexplanation of the components of power-pack 101, see U.S. ProvisionalPatent Application No. 62/060,734, filed Oct. 7, 2014, now U.S. patentapplication Ser. No. 14/863,558, filed Sep. 24, 2015, now U.S. PatentApplication Publication No. 2016/0095585, the entire contents of whichare incorporated herein by this reference.

Outer shell housing 10 includes a distal half-section 10 a and aproximal half-section 10 b pivotably connected to distal half-section 10a by a hinge 16 located along an upper edge of distal half-section 10 aand proximal half-section 10 b. Distal and proximal half-sections 10 a,10 b are divided along a plane that traverses a longitudinal axis “X-X”of surgical device 100.

Distal half-section 10 a includes a proximal facing edge 10 d, andproximal half-section 10 b includes a distal facing edge 10 e (see FIG.3). When distal and proximal half-sections 10 a, 10 b are joined,proximal facing edge 10 d of distal half-section 10 a and distal facingedge 10 e of proximal half-section 10 b define an interface 11 (see FIG.2) along the perimeter of the proximal and distal facing edges 10 d, 10e. At the same time, distal and proximal half-sections 10 a, 10 b definea shell cavity 10 c therein in which power-pack 101 is selectivelysituated.

Outer shell housing 10 may also include a sterile barrier plate assembly60 selectively supported in distal half-section 10 a. Specifically,sterile barrier plate assembly 60 is disposed behind connecting portion20 of distal half-section 10 a and within shell cavity 10 c of shellhousing 10.

Each of distal and proximal half-sections 10 a, 10 b of outer shellhousing 10 includes a respective upper shell portion 12 a, 12 b, and arespective lower shell portion 14 a, 14 b. Lower shell portions 14 a, 14b define a snap closure feature 18 for selectively securing lower shellportions 14 a, 14 b to one another and for maintaining outer shellhousing 10 in a closed condition.

When outer shell housing 10 is in a closed position, it is contemplatedthat interface 11 may employ a seal or gasket between the distalhalf-section 10 a and the proximal half-section 10 b to preventundesired materials from being introduced into shell cavity 10 c ofouter shell housing 10 and in turn, to power-pack 101, or fromcontaminants escaping from shell cavity 10 c and being introduced into asterile surgical environment. As such, in embodiments, the proximal anddistal facing edges 10 d, 10 e of distal and proximal half-sections 10a, 10 b, respectively, may include a seal or gasket, as shown in FIG. 4.

In particular, FIG. 4, which illustrates a cross-section of interface 11along the longitudinal axis “X-X,” shows a tongue and groove geometry inwhich the distal facing edge 10 e of proximal half-section 10 b definesa tongue 13 a and the proximal facing edge 10 d of distal half-section10 a defines a groove 13 b configured and shaped to receive the tongue13 a. While a tongue and groove geometry is shown, it is contemplatedthat any suitable seal geometry may be used to provide a seal atinterface 11.

In embodiments, distal half-section 10 a and proximal half-section 10 bof outer shell housing 10 may be fabricated from a polycarbonate orsimilar polymer. In embodiments, the material may be a transparent rigidpolymer. In embodiments, distal half-section 10 a and proximalhalf-section 10 b of outer shell housing 10 may be overmolded onto asubstrate. It is contemplated that the seal, as shown by example of thetongue and groove geometry in FIG. 4, may also be fabricated from apolycarbonate or similar polymer during this process, similar to distalhalf-section 10 a and proximal half-section 10 b.

With reference to FIGS. 5A-5F, it is further contemplated that anexternal seal insert or gasket 40 may be used alongside or in place of(see FIG. 5F) the interface configuration shown in FIG. 4 to provide asterile barrier between power-pack 101 and an operating room. Inembodiments, gasket 40 may be disposable or reposable up to apredetermined amount of uses and may include one or more anti-microbialsubstances incorporated therein.

It is contemplated that gasket 40 may be configured to compress into thegeometry of interface 11, such as, for example, the tongue and groovegeometry shown in FIGS. 5A-5E. To that end, gasket 40 may be a lowviscosity and low durometer material to allow gasket 40 to conform tothe geometry of interface 11.

Gasket 40 includes a body 40 a having a first side 41 a and a secondside 41 b. In embodiments, first side 41 a is located adjacent distalhalf-section 10 a of outer shell housing 10 and second side 41 b islocated adjacent proximal half-section 10 b of outer shell housing 10.However, in embodiments, the reverse orientation is possible. In orderto secure gasket 40 to interface 11, it is contemplated that first andsecond sides 41 a, 41 b may include a fixation mechanism, such as, forexample, an adhesive or any suitable fastener.

In embodiments, gasket 40 may include a reinforcing member, such as, forexample, a rod 42 as shown in FIGS. 5C and 5E. Rod 42 may be embeddedinto the body 40 a of gasket 40. In embodiments, rod 42 may beconfigured to add rigidity to gasket 40.

In embodiments, where interface 11 includes surface geometry ortopography, as shown for example in FIGS. 5C and 5E, rod 42 may beconfigured and sized to be integrated into the surface geometry ofinterface 11. For example, in FIGS. 5C and 5E, groove 13 b of distalhalf-section 10 a of outer shell housing 10 may include a diameter “D1”and rod 42 may include a diameter “D2,” where the diameter “D1” is equalto the diameter “D2.” As such, when the distal and proximalhalf-sections 10 a, 10 b are approximated, tongue 13 a of proximalhalf-section 10 b urges rod 42 of gasket 40 towards groove 13 b suchthat rod 42 of gasket 40 may be nested within groove 13 b while body 40a of gasket 40 conforms to the surrounding geometry of interface 11.

With specific reference to FIGS. 5A-5C and 5F, in embodiments, gasket 40may be pre-formed to the geometry of interface 11. For example, as shownin FIGS. 5B, 5C, and 5F, gasket 40 may include a substantially H-shapedcross-sectional profile. It is contemplated that the pre-formed gasket40 may be easier to locate on the proximal or distal facing edges 10 d,10 e of distal and proximal half-sections 10 a, 10 b, respectively.

In embodiments as shown in FIG. 5A, gasket 40 may include a line ofreduced thickness or a perforation line 40 b defined in body 40 a suchthat after gasket 40 is located in interface 11, a flange portion 40 cof gasket 40 may be removed along the perforation line 40 b.

It is contemplated that various methods and devices may be employed whenlocating gasket 40 on the interface 11 between distal and proximalhalf-sections 10 a, 10 b. In embodiments, medical personnel, such as,for example, a nurse may install the gasket 40 with their hands. To thatend, it is contemplated that gasket 40 may include a removable coating,such as, for example, a film 44 on each of first side 41 a and secondside 41 b (see FIG. 8) of gasket 40.

In operation, after removing the film 44 from one of the sides of gasket40, for example, from side 41 b, the medical personnel would place side41 b against the distal facing edge 10 e of proximal half-section 10 bof outer shell housing 10. With power-pack 101 inserted into shellcavity 10 c of shell housing 10, the medical personnel would then removethe remaining film (not expressly shown) from the opposite side, forexample, from side 41 a, and approximate the distal and proximalhalf-sections 10 a, 10 b of outer shell housing 10.

Alternatively, the gasket 40 may be incorporated into an insertion guide50, as detailed below, prior to being located in interface 11. Withreference to FIGS. 6-8, an insertion guide 50 configured and shaped toseat on and entirely surround the distal facing edge 10 e (see FIG. 3)of proximal half-section 10 b may be provided with surgical device 100.Insertion guide 50 is configured to space apart power-pack 101 and anouter surface 10 f (see FIGS. 6 and 7) of outer shell housing 10 toprevent undesired contact between power-pack 101 and outer surface 10 f.

Insertion guide 50 includes a body portion 52 having a substantiallyU-shaped transverse cross-sectional profile, and a stand-off 54extending from a bottom of body portion 52. Stand-off 54 is configuredto engage snap closure feature 18 of each of lower shell portions 14 a,14 b of respective distal and proximal half-sections 10 a, 10 b of shellhousing 10.

In use, when body portion 52 of insertion guide 50 is seated on distalfacing edge 10 e of proximal half-section 10 b, snap closure feature 18of lower shell portion 14 a of distal half-section 10 a engages a firstend of stand-off 54, and snap closure feature 18 of lower shell portion14 b of proximal half-section 10 b engages a first end of stand-off 54.

Body portion 52 also includes a track 56 on a proximal facing side 58 ofinsertion guide 50. Track 56 is configured to engage the distal facingedge 10 e of proximal half-section 10 b. In embodiments, track 56 mayalso be configured to receive gasket 40, as shown in FIG. 8. It iscontemplated that incorporating gasket 40 into track 56 of the insertionguide 50 may simplify the process of locating gasket 40 in interface 11as well as promote improved sterility of gasket 40, by limiting theamount of time that gasket 40 is handled by medical personnel. Oncegasket 40 is positioned in the desired location, it is contemplated thatgasket 40 may be released from insertion guide 50 using a mechanicalrelease, such as, for example, a latch or ejector 58 (see FIG. 8) orthrough gravity, leaving gasket 40 on the distal facing edge 10 e ofproximal half-section 10 b of outer shell housing 10 (see FIG. 9).

In operation, gasket 40 is pressed into track 56 of insertion guide 50and film 44 is removed from second side 41 b. Next, with a new and/orsterile outer shell housing 10 in an open configuration (i.e., distalhalf-section 10 a separated from proximal half-section 10 b, about hinge16), and with insertion guide 50, including gasket 40, in place againstthe distal edge of proximal half-section 10 b of shell housing 10,power-pack 101 is inserted into shell cavity 10 c of shell housing 10.With power-pack 101 inserted into shell cavity 10 c of shell housing 10,insertion guide 50 is removed from proximal half-section 10 b, leavingbehind gasket 40 on the distal facing edge 10 e of proximal half-section10 b. Removing the film (not expressly shown) on first side 41 a ofgasket 40, the distal half-section 10 a of outer shell housing 10 ispivoted, about hinge 16, to a closed configuration. In the closedconfiguration, snap closure feature 18 of lower shell portion 14 a ofdistal half-section 10 a engages snap closure feature 18 of lower shellportion 14 b of proximal half-section 10 b. In the closed configuration,gasket 40 compresses and migrates to fill in the geometry of interface11 as shown in FIGS. 5A-5F.

In operation, following a surgical procedure, snap closure feature 18 oflower shell portion 14 a of distal half-section 10 a is disengaged fromsnap closure feature 18 of lower shell portion 14 b of proximalhalf-section 10 b, and distal half-section 10 a is pivoted, about hinge16, away from proximal half-section 10 b to open shell housing 10. Withouter shell housing 10 open, power-pack 101 is removed from shell cavity10 c of outer shell housing 10 (specifically from proximal half-section10 b of shell housing 10), and outer shell housing 10 is discarded.Depending on the type of gasket 40 used, gasket 40 is either discardedwith outer shell housing 10 or reused after being sterilized. Power-pack101 is then disinfected and cleaned. Power-pack 101 is not to besubmerged or sterilized.

In accordance with the present disclosure, it is further contemplatedthat a kit 500 as shown in FIG. 10 may be provided. Kit 500 may includethe electromechanical surgical device 100 having the distal and proximalhalf-sections 10 a, 10 b of outer shell housing 10, the sterile barrierplate assembly 60, and the power-pack 101. The kit 500 may also includethe gasket 40 and the insertion guide 50. The kit 500 may furtherinclude instructions for the assembly of the electromechanical surgicaldevice 100, the use of the electromechanical surgical device 100, and apackage, container or box configured to retain the same.

Referring to FIGS. 11A and 11B, illustrated is an embodiment of areusable surgical instrument module 110, which shares similarities withpower-pack 101 of FIGS. 1-3. Instrument module 110 defines an upperinstrument module half 110A and a lower instrument module half 110B,upper instrument module half 110A defining a longitudinal axis “B.”Instrument module 110 also includes an inner housing shell 111 forincorporating a plurality of components therein, as described below.

Upper instrument module half 110A includes at least one motor 140, aswell as a display screen 160. At least one motor 140 is disposed withininner housing shell 111. A distal end 102 of upper instrument modulehalf 110A is configured to receive an end effector assembly. The endeffector assembly may be at least one of jaw members, a clip applier,vessel sealing devices, circular stapling devices, dissectors,retractors, cutters, graspers, and drills.

Lower instrument module half 110B includes a battery 120 (or energysource) and at least one control board 130. Battery 120 and at least onecontrol board 130 are disposed within inner housing shell 111. Lowerinstrument module half 110B is configured to be gripped by a user, suchas surgeon, during a surgical procedure. Additionally, upper instrumentmodule half 110A and lower instrument module half 110B may combine toform a substantially L-shaped or pistol-grip configuration.

At least one control board 130 is connected, on the one hand,electrically to battery 120, and, on the other hand, to at least onemotor 140. To this end, electric contacts (not shown) are provided on anupper side of battery 120 for establishing an electric connection withat least one control board 130. Additionally, at least one control board130 electrically communicates with at least one processor (not shown)for enabling flow of electrosurgical energy between the energy source(e.g., battery 120) and each motor 140.

Each motor 140 is configured to include, for instance, a drive shaft142. Drive shaft 142 defines an operative axis of rotation “B.” Eachmotor 140 is configured to actuate a function or operation of an endeffector assembly (not shown), including but not limited to,articulating, rotating, closing of the jaw members, ejecting fasteners,cutting, and the like.

Instrument module 110 may include a speaker 150 (see FIG. 11B), at aproximal end 104 thereof, for providing feedback information related totissue parameters and surgical instrument parameters measured during asurgical procedure. Speaker 150 may be used to provide audible feedback.Audible feedback may be used in conjunction with or in lieu of thevisual outputs.

Instrument module 110 may include display screen 160 disposed thereindisplaying information related to tissue parameters and surgicalinstrument parameters measured during a surgical procedure. Displayscreen 160 may be configured to provide the surgeon with a variety ofsuitable output information. Display screen 160 may include at least oneof numerical indicators and color indicators.

Instrument module 110 may also include a clamp button 170 and a returnbutton 180. Clamp button 170 may be configured to actuate an endeffector assembly (not shown) connected to distal end 102 of instrumentmodule 110 to a first position. End effector assembly may be a pair ofjaw members for clamping tissue in the first position. Return button 180may be configured to return the jaw members to an open, unclampedposition (or second position).

Referring to FIG. 12, a method of inserting a reusable surgicalinstrument module 110 into an outer housing shell 280 having a hingedinstrument cover shell 290, in accordance with an embodiment of thepresent disclosure is presented.

Outer housing shell 280 defines a cavity 282 therein. Outer housingshell 280 defines an upper outer housing half 280A and a lower outerhousing half 280B. Upper outer housing half 280A defines a longitudinalaxis “A” extending therethrough. Outer housing shell 280 also includesinstrument shell cover 290 connected to lower outer housing half 280Bvia a hinged connection 292. Instrument shell cover 290 may rotate orpivot in direction “C” after instrument module 110 has been fullyinserted into outer housing shell 280, as described below. In accordancewith an embodiment of the present disclosure, outer housing shell 280may be devoid of movable switches.

In operation or use, instrument module 110 is inserted into cavity 282of outer housing shell 280 in such a manner that operative axis “B” ofat least one motor 140 is substantially parallel to longitudinal axis“A” of upper outer housing half 280A. Stated differently, instrumentmodule 110 is configured to be inserted into reusable outer housingshell 280, such that instrument module 110 is inserted and extractedalong an axis of operation of at least one motor 140 or alonglongitudinal axis “B.” Upper instrument module half 110A is configuredto underlie or nest upper outer housing half 280A, whereas lowerinstrument module half 110B is configured to underlie or nest lowerouter housing half 280B. Once instrument shell 110 is fully insertedinto outer housing shell 280, instrument shell cover 290 is rotated, indirection “C,” in order to create a secure seal with outer housing shell280.

Following a surgical procedure, instrument shell cover 290 is opened andinstrument module 110 is withdrawn from or removed from cavity 282 ofouter housing shell 280 such that outer housing shell 280 and shellcover 290 may be cleaned in accordance with methods and procedures knownin the art, for example, sterilizing, autoclaving, steam cleaning,wiping with cleaning products/solvents and the like. Thus, outer housingshell 280 and shell cover 290 may be cleaned or sterilized withoutcompromising instrument module 110 inserted therein. Once cleaning orsterilization has been completed, instrument module 110 may bere-introduced into cavity 282 of outer housing shell 280 prior toperforming a further surgical procedure.

Referring to FIG. 13, a method of inserting a reusable surgicalinstrument module 110 into an outer housing shell 380 having a snapableinstrument cover shell 390, in accordance with another embodiment of thepresent disclosure is illustrated.

Outer housing shell 380 defines a cavity 382 therein. Outer housingshell 380 defines an upper outer housing half 380A and a lower outerhousing half 380B. Upper outer housing half 380A defines a longitudinalaxis “D” extending therethrough. Lower outer housing half 380B of outerhousing shell 380 may connect or attach to instrument shell cover 390via, for example, a snapable mechanism including fasteners (not shown).Additionally, a clear viewing window 385 may be constructed so that itoverlays a display screen (e.g., as described above with reference toFIGS. 11A and 11B). Viewing window 385 is designed for viewing thedisplay screen disposed therein displaying information related to tissueparameters and surgical instrument parameters measured during a surgicalprocedure.

In accordance with the present disclosure, it is contemplated that outerhousing shell 380 (as well as outer housing shells 180, 280) may befabricated from a translucent or transparent material, such as, forexample, a polycarbonate resin thermoplastic. As so constructed, indiciafrom display screen 160 of instrument module 110 or the like. It isfurther contemplated that at least a portion of outer housing shell 380may be translucent or transparent.

In operation or use, instrument module 110 is inserted into cavity 382of outer housing shell 380 in such a manner that operative axis “E” ofat least one motor 140 (or of at least one drive shaft 142) issubstantially parallel to longitudinal axis “D” of upper outer housinghalf 110A. Stated differently, instrument module 110 is configured to beinserted into instrument outer housing shell 380, such that instrumentmodule 110 is inserted and extracted along an axis of operation of atleast one motor 140, or along longitudinal axis “E.” Upper instrumentmodule half 110A is configured to underlie or nest upper outer housinghalf 380A, whereas lower instrument module half 110B is configured tounderlie or nest lower outer housing half 380B. Once instrument shellcover 390 is attached to a portion of lower outer housing half 380B,instrument module 110 is inserted into outer housing shell 380 such thatupper outer housing half 380A and the remaining portion of the lowerouter housing half 380B lock or secure or seal with instrument shellcover 390 along connection region 395.

Following a surgical procedure, instrument shell cover 390 is withdrawnor unsnapped from lower outer housing half 380B (at connection region395) and instrument module 110 is withdrawn from or removed from cavity382 of outer housing shell 380 such that outer housing shell 380 andshell cover 390 may be cleaned in accordance with methods and proceduresknown in the art. Thus, outer housing shell 380 may be cleaned orsterilized without compromising instrument module 110 inserted therein.Once cleaning or sterilization has been completed, instrument module 110may be re-introduced into cavity 382 of outer housing shell 380 prior toperforming a further surgical procedure.

Turning now to FIG. 14, in accordance with the present disclosure, it iscontemplated that outer housing shell 280, 380 may define a plurality ofapertures 150 through which each drive shaft 142 passes. A seal 152 isprovided in each aperture 150 and is supported therein so as to remainwith outer housing shell 280, 380 during insertion/retraction ofinstrument module 110 therein/therefrom. Seals 152 may take the form ofO-rings or the like, and may be constructed from a resilient, polymericmaterial, such as, for example, rubber. Seals 152 are configured anddimensioned to establish a fluid-tight seal between outer housing shell280, 380 and drive shafts 142. Additionally, seals 152 are configuredand dimensioned to permit drive shafts 142 to rotate. In use, when shellcovers 290, 390 are closed against respective outer housing shells 280,380, a force is exerted against instrument module 110, substantiallyalong or in direction “B”, to thereby press a distal surface of upperinstrument module half 110A against seals 152 and establish afluid-tight seal against an outer surface of drive shafts 142.

It will be understood that various modifications may be made to theembodiments disclosed above. For example, gasket 40 of FIGS. 1-10 may belocated using a specialized tool or track in place of the insertionguide 50. It its contemplated that the specialized tool or track may besterilized using an autoclave or similar device.

Therefore, the above description should not be construed as limiting,but merely as exemplifications of embodiments. Those skilled in the artwill envision other modifications within the scope and spirit of thepresent disclosure.

1-14. (canceled)
 15. An electromechanical surgical device, comprising:an outer shell housing including: a distal section having an edge thatdefines an opening into the distal section; a proximal section having anedge that defines an opening into the proximal section, the distal andproximal sections together defining an internal cavity when the distaland proximal sections are coupled to one another; and a seal configuredto be positioned between the edge of the distal section and the edge ofthe proximal section to provide a sterile barrier between the internalcavity and an environment outside the outer shell housing.
 16. Theelectromechanical surgical device according to claim 15, furthercomprising an insertion guide configured to be seated on the edge of theproximal or distal sections for guiding a power-pack into the internalcavity.
 17. The electromechanical surgical device according to claim 16,wherein the insertion guide includes a body portion having a sideconfigured for attachment of the seal.
 18. The electromechanicalsurgical device according to claim 17, wherein the side of the bodyportion of the insertion guide defines a track configured for receipt ofthe seal.
 19. The electromechanical surgical device according to claim18, wherein the track is configured for receipt of the edge of theproximal or distal sections.
 20. The electromechanical surgical deviceaccording to claim 16, wherein the insertion guide includes a bodyportion that surrounds the edge of the proximal or distal sections whenthe insertion guide is engaged with the edge of the proximal or distalsections.
 21. The electromechanical surgical device according to claim20, wherein the body portion has a side defining a track configured forreceipt of the edge of the proximal or distal sections.
 22. Theelectromechanical surgical device according to claim 15, wherein theedge of the proximal section includes one of a groove or a projection,and the edge of the distal section includes the other of the groove orthe projection.
 23. The electromechanical surgical device according toclaim 22, wherein the groove extends at least partially around aperiphery of the edge of the proximal or distal sections, and theprojection extends at least partially around a periphery of the other ofthe edge of the proximal or distal sections.
 24. The electromechanicalsurgical device according to claim 15, wherein the distal and proximalsections of the outer shell housing are movable relative to one anotherbetween a first position, in which the edge of the distal section andthe edge of the proximal section are spaced apart from one another, anda second position, in which the edge of the distal section and the edgeof the proximal section are approximated.
 25. A method of assembling anelectromechanical surgical device, comprising: inserting a power-packinto a proximal section or a distal section of an outer shell housing;closing the outer shell housing by approximating the proximal and distalsections to encase the power-pack within a cavity cooperatively definedby the proximal and distal sections of the outer shell housing, whereinclosing the outer shell housing includes compressing a seal between anedge of the proximal section and an edge of the distal section.
 26. Themethod according to claim 25, wherein the edge of the proximal sectionhas a groove or a projection and the edge of the distal section has theother of the groove or the projection, such that the seal is compressedbetween the groove and the projection.
 27. The method according to claim25, further comprising passing the power-pack through an insertion guideprior to inserting the power-pack into the proximal section or thedistal section, the insertion guide being coupled to the proximalsection or the distal section of the outer shell housing.
 28. The methodaccording to claim 27, further comprising detaching the insertion guidefrom the outer shell housing prior to closing the outer shell housing.29. The method according to claim 28, wherein detaching the insertionguide includes detaching the insertion guide from the seal, therebyleaving the seal attached to the edge of the proximal or distalsections.
 30. The method according to claim 29, wherein detaching theinsertion guide from the seal includes removing the seal from a trackdefined in a side of the insertion guide.
 31. The method according toclaim 30, further comprising removing a film that covers a side of theseal after the insertion guide is detached from the outer shell housing,wherein closing the outer shell housing includes contacting the edge ofthe proximal or distal sections with an adhesive disposed on the side ofthe seal.
 32. The method according to claim 27, further comprisingsurrounding the edge of the proximal or distal sections with a bodyportion of the insertion guide prior to inserting the power-pack intothe outer shell housing.